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Tahoe / Yukon Service Manual

Fuel Injector Fuel Return Pipe Replacement

Single Use Fasteners and Components Exhaust Gas Recirculation Cooler Inlet Pipe Gasket Exhaust Gas Recirculation Pipe Seal

  1. Turn OFF the engine for 30 seconds before proceeding to purge the fuel pressure from the complete fuel system.
  2. Plenum Front Panel Outer Reinforcement » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation
Fuel Injector Fuel Return Pipe Replacement — figure 1
Fuel Injector Fuel Return Pipe Replacement — figure 1
  1. Oil Filler Cap » Remove
  2. Intake Manifold Cover Bolt (1) » Remove
  3. Intake Manifold Cover (2) » Remove
  4. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.
Fuel Injector Fuel Return Pipe Replacement — figure 2
Fuel Injector Fuel Return Pipe Replacement — figure 2
  1. Air Cleaner Outlet Front Duct Clamp (1) » Loosen [2x]
  2. Air Cleaner Outlet Front Duct (2) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 3
Fuel Injector Fuel Return Pipe Replacement — figure 3
  1. Air Cleaner Outlet Duct Clamp (1) » Loosen
  2. Air Cleaner Outlet Duct (2) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 4
Fuel Injector Fuel Return Pipe Replacement — figure 4
  1. Remove the 3 engine wiring harness bracket nuts (1).
  2. Position the rear engine wiring harness channel (2) out of the way.
Fuel Injector Fuel Return Pipe Replacement — figure 5
Fuel Injector Fuel Return Pipe Replacement — figure 5
  1. Engine Coolant Outlet Pipe Bracket Bolt (1) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 6
Fuel Injector Fuel Return Pipe Replacement — figure 6
  1. Engine Coolant Air Bleed Hose (2) » Reposition
Fuel Injector Fuel Return Pipe Replacement — figure 7
Fuel Injector Fuel Return Pipe Replacement — figure 7
  1. Remove the 2 exhaust gas recirculation outlet pipe bolts (1).
Fuel Injector Fuel Return Pipe Replacement — figure 8
Fuel Injector Fuel Return Pipe Replacement — figure 8
  1. Remove the turbocharger coolant feed and return pipe bolt (3) and position the turbocharger coolant feed pipe (2) out of the way.
Fuel Injector Fuel Return Pipe Replacement — figure 9
Fuel Injector Fuel Return Pipe Replacement — figure 9
  1. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
  2. Remove the exhaust gas recirculation outlet pipe bolt (2).
Fuel Injector Fuel Return Pipe Replacement — figure 10
Fuel Injector Fuel Return Pipe Replacement — figure 10
  1. Remove the 2 exhaust gas recirculation pipe bolts (1).
Fuel Injector Fuel Return Pipe Replacement — figure 11
Fuel Injector Fuel Return Pipe Replacement — figure 11
  1. Exhaust Gas Recirculation Pipe (1) » Remove
  2. Exhaust Gas Recirculation Pipe Seal (2) » Remove and DISCARD
  3. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) » Remove and DISCARD
Fuel Injector Fuel Return Pipe Replacement — figure 12
Fuel Injector Fuel Return Pipe Replacement — figure 12
  1. Electrical Connector (1) @ Nitrogen Oxides Sensor » Disconnect
  2. Wiring Harness Retainer (2) @ Charge Air Cooler » Remove [3x]
  3. Electrical Connector (3) @ Charge Air Cooler » Disconnect [2x]
  4. Engine Wiring Harness (4) » Position aside
Fuel Injector Fuel Return Pipe Replacement — figure 13
Fuel Injector Fuel Return Pipe Replacement — figure 13
  1. Wiring Harness Retainer (4) @ Charge Air Cooler » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 14
Fuel Injector Fuel Return Pipe Replacement — figure 14
  1. Charge Air Cooler Outlet Air Hose Clamp (1) » Loosen until disengaged [2x]
  2. Charge Air Cooler Outlet Air Hose (2) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 15
Fuel Injector Fuel Return Pipe Replacement — figure 15
  1. Charge Air Cooler Inlet Air Hose Clamp (1) » Loosen until disengaged [2x]
  2. Charge Air Cooler Inlet Air Hose (2) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 16
Fuel Injector Fuel Return Pipe Replacement — figure 16
  1. Charge Air Cooler Bolt (1) » Remove [4x]
Fuel Injector Fuel Return Pipe Replacement — figure 17
Fuel Injector Fuel Return Pipe Replacement — figure 17
  1. Reposition charge air cooler (1) with coolant hoses attached.
Fuel Injector Fuel Return Pipe Replacement — figure 18
Fuel Injector Fuel Return Pipe Replacement — figure 18
  1. Upper Intake Manifold Brace Nut (1) » Remove [3x]
  2. Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor.
Fuel Injector Fuel Return Pipe Replacement — figure 19
Fuel Injector Fuel Return Pipe Replacement — figure 19
  1. Turbocharger Heat Shield Bolt (1) » Remove [2x]
  2. Turbocharger Heat Shield Nut (2) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 20
Fuel Injector Fuel Return Pipe Replacement — figure 20
  1. Reposition the turbocharger heat shield (1) with the exhaust gas recirculation temperature sensor attached.
Fuel Injector Fuel Return Pipe Replacement — figure 21
Fuel Injector Fuel Return Pipe Replacement — figure 21
  1. Release the retaining spring (1).
  2. Intake Manifold Resonator (2) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 22
Fuel Injector Fuel Return Pipe Replacement — figure 22
  1. Turbocharger Bracket Bolt (1) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 23
Fuel Injector Fuel Return Pipe Replacement — figure 23
  1. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
  2. Engine Wiring Harness Bracket (3) » Reposition
Fuel Injector Fuel Return Pipe Replacement — figure 24
Fuel Injector Fuel Return Pipe Replacement — figure 24
  1. Oil Filler Tube Support Stud (1) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 25
Fuel Injector Fuel Return Pipe Replacement — figure 25
  1. Engine Coolant Air Bleed Hose Clip (1) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 26
Fuel Injector Fuel Return Pipe Replacement — figure 26
  1. Charge Air Cooler Bolt (1) » Remove [5x]
  2. Charge Air Cooler Bracket (2) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 27
Fuel Injector Fuel Return Pipe Replacement — figure 27
  1. Reposition harness and hoses, and connect electrical connectors as needed.
  2. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Remove
  3. Exhaust Gas Recirculation Pipe Bracket (5) » Remove
Fuel Injector Fuel Return Pipe Replacement — figure 28
Fuel Injector Fuel Return Pipe Replacement — figure 28

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 51. Camshaft Housing Cover Insulator (1) » Remove

Fuel Injector Fuel Return Pipe Replacement — figure 29
Fuel Injector Fuel Return Pipe Replacement — figure 29
  1. Disconnect and reposition the fuel injector wiring harness as needed.
  2. Retainer (1) » Disengage
  3. Fuel Injector Fuel Return Pipe Clamp (2) » Disengage — Hose Clamp Replacement Guidelines
  • Spring Type
  1. Retainer (3) » Remove
  2. Fuel Injection Fuel Return Pipe Locking Spring (4) » Disengage [6x]
Fuel Injector Fuel Return Pipe Replacement — figure 30
Fuel Injector Fuel Return Pipe Replacement — figure 30
  1. Fuel Injection Fuel Return Pipe (1) » Remove Cleaning and Inspection Procedure - Required
Fuel Injector Fuel Return Pipe Replacement — figure 31
Fuel Injector Fuel Return Pipe Replacement — figure 31
  1. Inspect the charge air cooler inlet air hose (2): 1.1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 1.2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found. 1.3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.
Fuel Injector Fuel Return Pipe Replacement — figure 32
Fuel Injector Fuel Return Pipe Replacement — figure 32

  1. Inspect the charge air cooler outlet air hose (2): 2.1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 2.2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found. 2.3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing. Installation Procedure

  2. Fuel Injection Fuel Return Pipe (1) » Install

  3. Fuel Injection Fuel Return Pipe Locking Spring (4) » Engage [6x]

  4. Retainer (3) » Install

  5. Fuel Injector Fuel Return Pipe Clamp (2) » Engage — Hose Clamp Replacement Guidelines - Spring Type

  6. Retainer (1) » Engage

  7. Install and connect the fuel injector wiring harness as needed.

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.  7. Camshaft Housing Cover Insulator (1) » Install

  1. Exhaust Gas Recirculation Pipe Bracket (5) » Install

  1. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

  2. Reposition harness and hoses, and connect electrical connectors as needed.

  3. Charge Air Cooler Bracket (2) » Install

  4. Charge Air Cooler Bolt (1) » Install [5x] — Fastener Specifications

  5. Engine Coolant Air Bleed Hose Clip (1) » Install

  6. Oil Filler Tube Support Stud (1) » Install — Fastener Specifications

  7. Engine Wiring Harness Bracket (3) » Install

  8. Engine Wiring Harness Bracket Nut (1) » Install [2x] — Fastener Specifications

  9. Turbocharger Bracket Bolt (1) » Install and tighten — Fastener Specifications

  10. Intake Manifold Resonator (2) » Install

  11. Engage the retaining spring (1).

  12. Turbocharger Heat Shield (1) » Install

  13. Turbocharger Heat Shield Nut (2) » Install and tighten — Fastener Specifications

  14. Turbocharger Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

  15. Charge Air Cooler (1) » Install

  16. Charge Air Cooler Bolt (1) » Install [4x] — Fastener Specifications

  17. Charge Air Cooler Inlet Air Hose (2) » Install

  18. Charge Air Cooler Inlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

  19. Charge Air Cooler Outlet Air Hose (2) » Install

  20. Charge Air Cooler Outlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

  21. Instal the upper intake manifold bracket (2) with the nitrogen oxides sensor.

  22. Upper Intake Manifold Brace Nut (1) » Install and tighten [3x] — Fastener Specifications

  23. Wiring Harness Retainer (4) @ Charge Air Cooler » Install

  24. Engine Wiring Harness (4) » Reposition

  25. Wiring Harness Retainer (2) @ Charge Air Cooler » Install [3x]

  26. Electrical Connector (3) @ Charge Air Cooler » Connect [2x]

  27. Electrical Connector (1) @ Nitrogen Oxides Sensor » Connect

  28. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) » Install NEW

  29. Exhaust Gas Recirculation Pipe Seal (2) » Install NEW

  30. Exhaust Gas Recirculation Pipe (1) » Install

Fuel Injector Fuel Return Pipe Replacement — figure 33
Fuel Injector Fuel Return Pipe Replacement — figure 33

  1. Install and hand tighten the 2 exhaust gas recirculation outlet pipe bolts (1).

  2. Exhaust Gas Recirculation Outlet Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications.

  3. Exhaust Gas Recirculation Outlet Pipe Bolt (2) » Install and tighten — Fastener Specifications

  4. Install the turbocharger coolant return hose clip (1).

  5. Install and tighten the turbocharger coolant feed and return pipe bolt (3). Fastener Specifications

  1. Exhaust Gas Recirculation Cooler Bolt (1) » Install and tighten [2x] — Fastener Specifications.

  2. Engine Coolant Air Bleed Hose (2) » Install

  3. Engine Coolant Outlet Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

  4. Install the rear engine wiring harness channel (2).

  5. Install the 3 engine wiring harness bracket nuts (1) and tighten. Fastener Specifications

  6. Air Cleaner Outlet Duct (2) » Install

  7. Air Cleaner Outlet Duct Clamp (1) » Tighten — Fastener Specifications

  8. Air Cleaner Outlet Front Duct (2) » Install

  9. Air Cleaner Outlet Front Duct Clamp (1) » Tighten [2x] — Fastener Specifications

  10. Oil Filler Cap » Remove

  11. Intake Manifold Cover (2) » Install

  12. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

  13. Oil Filler Cap » Install

  14. Plenum Front Panel Outer Reinforcement » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

  15. Prime the fuel system and inspect for leaks. Fuel System Priming

  16. Inspect the exhaust system for leaks.